Methods and Apparatuses for Transferring Absorbent Articles and Rejecting Defective Absorbent Articles

ABSTRACT

The present disclosure relates to methods and apparatuses for rejecting defective absorbent articles from a converting line. At a downstream portion of a converting process, a continuous length of absorbent articles may be subjected to a final knife and cut to create discrete absorbent articles advancing on a first carrier. From the first carrier, the discrete absorbent articles may be transferred to a transfer apparatus, which in turn, transfers the discrete absorbent articles to a second carrier. The transfer apparatus may include carrier members that orbit around an axis of rotation and may be adapted to receive the absorbent articles from the first carrier and transfer the absorbent articles to the second carrier. Defective absorbent articles may be detected by an inspection system, which may be operably connected with the transfer apparatus and/or the first carrier to remove the defective absorbent articles from the converting process.

FIELD OF THE INVENTION

The present disclosure relates to systems and methods for manufacturingdisposable absorbent articles, and more particularly, systems andmethods for detecting and rejecting defective absorbent articles from aconverting line.

BACKGROUND OF THE INVENTION

Along an assembly line, diapers and various types of other absorbentarticles may be assembled by adding components to and otherwisemodifying an advancing, continuous web of material. For example, in someprocesses, advancing webs of material are combined with other advancingwebs of material. In other examples, individual components created fromadvancing webs of material are combined with advancing webs of material,which in turn, are then combined with other advancing webs of material.Webs of material and component parts used to manufacture diapers mayinclude: backsheets, topsheets, absorbent cores, front and/or back ears,fastener components, and various types of elastic webs and componentssuch as leg elastics, barrier leg cuff elastics, and waist elastics.Once the desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles. The discretediapers or absorbent articles may also then be folded and packaged.

For quality control purposes, absorbent article converting lines mayutilize various types of sensors to detect defects in the webs anddiscrete components added to the webs along the converting line asabsorbent articles are constructed. Example sensor technology mayinclude vision systems, photoelectric sensors, proximity sensors, laseror sonic distance detectors, and the like. Sensor data may becommunicated to a controller. In turn, the controller may be programmedto receive sensor data and reject or cull defective diapers after thefinal knife cut at the end of the converting line.

Various systems are used for rejecting defective diapers, such as bydiverting the defective diapers from the stream of diapers that are ofsatisfactory condition or good quality. For example, one system that hasbeen used to reject cut web products includes forcing the defectivediapers out of the stream of satisfactory products by using pneumaticair blasts, which divert the defective diapers to a path that differsfrom that for the stream of satisfactory diapers. In such a method, thedefective diapers are detected, and a pneumatic air blast from one ormore nozzles forces the defective diapers out of the stream of qualityproducts and into a reject bin provided in proximity of the conveyorsystem or production line. Such existing systems of rejecting cut webproducts using pneumatic air blasts may have some disadvantages. Forexample, a separate system having pneumatic nozzles and associated hosesand/or piping require space, such as for example, extra space along theconveyor system. In addition, such systems may not be entirely accurateand can divert more than solely the defective diapers from the stream ofsatisfactory products.

Other methods of rejecting defective diapers may include mechanicallyactivated switches, or flippers, that divert the defective cut webproducts to an alternative pathway, similar to the manner railwayswitches can divert trains to a different track. The mechanical switchesare may be activated via a pneumatic or hydraulic cylinder or via anelectric motor. Some configuration may include mechanical switches thatpop up from the conveyor system and divert the defective diapers belowthe switch and toward an alternate pathway. With such mechanicallyoperated systems, more space may be required to accommodate themechanically activated switches. Thus, space consumption is adisadvantage to the mechanical switch method. Furthermore, theadditional mechanical switch equipment may result in added complexityand cost.

Consequently, it would be beneficial to provide a relatively lesscomplex and less spacious system for high speed selective redirectingand/or rejecting of absorbent articles. In addition, a method andapparatus that is relatively more accurate in removing only thedefective absorbent articles from the stream of quality products mayalso be desirable. Further, a system that utilizes some existingconverting equipment and control mechanisms to reject products ratherthan a completely separate system to perform redirecting and/orrejecting operations may be desirable.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for rejectingdefective absorbent articles from a converting line. At a downstreamportion of a converting process, a continuous length of absorbentarticles may be subjected to a final knife and cut to create discreteabsorbent articles advancing on a first carrier. From the first carrier,the discrete absorbent articles may be transferred to a transferapparatus, which in turn, transfers the discrete absorbent articles to asecond carrier. The transfer apparatus may include carrier members thatorbit around an axis of rotation and may be adapted to receive theabsorbent articles from the first carrier and transfer the absorbentarticles to the second carrier. Defective absorbent articles may bedetected by an inspection system, which may be operably connected withthe transfer apparatus and/or the first carrier to remove the defectiveabsorbent articles from the converting process.

A method for rejecting defective absorbent articles from a webconverting manufacturing process may include the steps of: converting asubstrate and component parts into a continuous length of absorbentarticles; inspecting the substrate or component parts with a sensor;communicating inspection parameters from the sensor to a controller;cutting the continuous length of absorbent articles into discreteabsorbent articles; identifying defective discrete absorbent articlesbased on the inspection parameters; advancing the discrete absorbentarticles in a machine direction on a first carrier; transferringdiscrete absorbent articles from the first carrier onto carrier membersat a first position proximate the first carrier; applying a vacuumpressure to the carrier members to hold the discrete absorbent articleson the carrier members; moving carrier members from the first positionproximate the first carrier to a second position proximate a secondcarrier; and transferring discrete absorbent articles from the carriermembers to the second carrier; and rejecting defective discreteabsorbent articles before the defective absorbent articles aretransferred to the second carrier.

A method for rejecting defective absorbent articles from a webconverting manufacturing process may include the steps of: converting asubstrate and component parts into a continuous length of absorbentarticles; inspecting the substrate or component parts with a sensor;communicating inspection parameters from the sensor to a controller;cutting the continuous length of absorbent articles into discreteabsorbent articles; identifying defective discrete absorbent articlesbased on the inspection parameters; advancing the discrete absorbentarticles in a machine direction on a first carrier; orbiting the carriermembers about a first axis of rotation; transferring discrete absorbentarticles in a first orientation from the first carrier onto the carriermembers; applying a vacuum pressure to the carrier members to hold thediscrete absorbent articles on the carrier members; rotating the carriermembers about a second axis of rotation to place the discrete absorbentarticles in a second orientation; and transferring discrete absorbentarticles from the carrier members to the second carrier in the secondorientation; and rejecting defective discrete absorbent articles beforethe defective absorbent articles are placed in the second orientation.

A system for rejecting defective absorbent articles may include: astator member including an arc shaped manifold, a first port, and asecond port; an arc shaped insert positioned inside the manifold andmovably connected with the manifold, wherein a portion of the manifoldhousing the insert defines a first zone, and a remaining portion of themanifold defines a second zone; an actuator connected with the insertand adapted to move the insert to a first position and a secondposition, wherein the first zone of the manifold is in fluidcommunication with the first port when insert is in the first position,and the first zone of the manifold is in fluid communication with thesecond port when the insert is in the second position; a support memberextending radially outward from a first axis of rotation and adapted torotate about the first axis of rotation; and a carrier member connectedwith the support member, the carrier member including an aperturedcarrier surface, the aperture carrier surface being in intermittentfluid communication with the manifold as the support member rotatesabout the first axis of rotation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a diaper pant.

FIG. 2A is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 2B is a partially cut away plan view of a second embodiment of adiaper pant.

FIG. 3A is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3B-3B.

FIG. 4 is a schematic side view of a converting apparatus adapted tomanufacture diapers.

FIG. 5A is a view of multiple discrete chassis connected with front andback side panel material and being folded to place the front and backside panel material in a facing relationship from FIG. 4 taken alongline 5A-5A.

FIG. 5B is a view of folded multiple discrete chassis with the front andback side panel material in a facing relationship from FIG. 4 takenalong line 5B-5B.

FIG. 5C is a view of two discrete absorbent articles oriented such thatthe longitudinal axis is generally perpendicular to the machinedirection MD from FIG. 4 taken along line 5C-5C.

FIG. 5D is a view of two discrete absorbent articles oriented such thatthe longitudinal axis is generally parallel with the machine directionMD from FIG. 4 taken along line 5D-5D.

FIG. 6 is a detailed schematic view of an embodiment a first carrier andcarrier apparatus along with associated pneumatic systems.

FIG. 7A is a cross sectional view of a pneumatic system operablyconnected with the first carrier in a first mode of operation from FIG.6 taken along line 7-7.

FIG. 7B is a cross sectional view of the pneumatic system operablyconnected with the second carrier in a first mode of operation from FIG.6 taken along line 7-7.

FIG. 8A is a cross sectional view of the rotary valve assembly from FIG.7A taken along line 8-8.

FIG. 8B is a cross sectional view of the rotary valve assembly from FIG.7B taken along line 8-8.

FIG. 9 a schematic view of a manifold valve assembly operably connectedwith the transfer apparatus from FIG. 6.

FIG. 10A is a cross sectional view of a pneumatic system and manifoldvalve assembly operably connected with the transfer apparatus in a firstmode of operation from FIG. 9 taken along line 10-10.

FIG. 10B is a cross sectional view of a pneumatic system and manifoldvalve assembly operably connected with the transfer apparatus in asecond mode of operation from FIG. 9 taken along line 10-10.

FIG. 11 is a cross sectional view of a pneumatic system and manifoldvalve assembly operably connected with the transfer apparatus from FIG.9 taken along line 11-11.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a defined woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed.

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

The present disclosure relates to methods and apparatuses formanufacturing absorbent articles, and more particularly, systems andmethods for detecting and rejecting defective absorbent articles from aconverting line. As discussed in more detail below, during theconverting process, various continuous substrates and/or discretecomponents may be combined with each other to form a continuous lengthof absorbent articles. At a downstream portion of the convertingprocess, the continuous length of absorbent articles may be subjected toa final knife and cut to create separate and discrete absorbent articlesin the form of diapers. The discrete absorbent articles may then advancein a machine direction MD in a first orientation on a first carrier.From the first carrier, the discrete absorbent articles are transferredto a transfer apparatus. The transfer apparatus, in turn, transfers thediscrete absorbent articles to a second carrier in a second orientationthat is different from the first orientation. More particularly, thetransfer apparatus rotates around an axis of rotation, and may includecarrier members that orbit around the axis of rotation. The carriermembers are adapted to receive the absorbent articles in the firstorientation from the first carrier and transfer the absorbent articlesto the second carrier in the second orientation. As such, the absorbentarticles may be transferred in a first orientation from the firstcarrier to the carrier members in a pick-up zone, and the absorbentarticles may be transferred in a second orientation from the carriermembers to the second carrier in a drop-off zone. As discussed in moredetail below, defective absorbent articles may be detected and trackedby an inspection system. In turn, the inspection system may be operablyconnected with the transfer apparatus and/or the first carrier to removethe defective absorbent articles from the converting process. Absorbentarticles that are not deemed to be defective may be transferred to thesecond carrier from the transfer apparatus and subject to furtherprocessing steps, such as for example, side panel tucking and packagingoperations.

As discussed in more detail below, the inspection system may beconfigured to operate with the transfer apparatus and/or first carrierin various ways to remove defective absorbent articles from themanufacturing process. In some embodiments, the first carrier mayinclude a vacuum source that applies suction forces to hold theabsorbent articles to the first carrier as the absorbent articlesadvance to the pick-up zone. The first carrier may also include apositive pressure source that “blows-off” or pushes the absorbentarticles away from the first carrier at or downstream of the pick-upzone. Further, the carrier members on the transfer apparatus may befluidly connected with a vacuum source that applies suction forces tohold the absorbent articles on the carrier members while moving from thefirst carrier to the second carrier. As such, the inspection system maybe operably connected with vacuum and/or positive pressures systemsassociated with the transfer apparatus and/or the first carrier toreject and redirect defective absorbent articles from the convertingprocess.

In some configurations, the inspection system may be configured toreject defective absorbent articles after the defective absorbentarticles have been transferred to a carrier member on the transferapparatus. For example, the inspection system may be operable totemporarily disconnect the vacuum system from the carrier member holdingthe defective absorbent article. As such, the defective absorbentarticle is no longer held to the carrier member with suction forces, andin turn, may be channeled or redirected from the carrier member to areject bin. In some embodiments, the inspection system may be operableto disconnect the vacuum source and then temporarily connect a positiveair pressure source with the carrier member holding the defectivearticle. As such, the positive air pressure source acts to push or“blow-off” the defective absorbent article from the carrier member.

In some embodiments, the inspection system may be configured to rejectdefective absorbent articles by preventing the defective absorbentarticles from being transferred to the carrier members on the transferapparatus. For example, the inspection system may be operable totemporarily disengage the vacuum system from the carrier member near orat the pick-up zone before the carrier member picks up a defectiveabsorbent article from the first carrier. In addition, the inspectionsystem may be operable to maintain the vacuum system connection with thefirst carrier in the pick-up zone. As such, suction forces from thevacuum system continue to hold the defective absorbent article on thefirst carrier as the defective absorbent article advances into thepick-up zone. In addition, suction forces may be maintained to the holdthe defective absorbent article on the first carrier as the defectiveabsorbent article advances past the pick-up zone.

It is to be appreciated that with respect to the transfer apparatus, thefirst orientation and the second orientation may be described in variousways. For example, as discussed in more detail below, the firstorientation may be described by reference to some physical aspect orcomponent of an advancing absorbent article relative to the machinedirection MD or cross direction CD. In some embodiments, the firstorientation may be described as having a longitudinal axis of eachabsorbent article oriented in a cross direction CD or beingperpendicular or generally perpendicular to the machine direction MD. Asmentioned above, the absorbent articles may then advance to the transferapparatus that positions the advancing absorbent articles in a secondorientation. The second orientation may for example be described ashaving the advancing absorbent articles being turned by some angle withrespect to the first orientation, such as for example, having beenturned 90° or 180° with respect to the first orientation. In someembodiments, the second orientation may be described as having thelongitudinal axis of each advancing absorbent article oriented so as tobe parallel or generally parallel with the machine direction MD.

It is to be appreciated that although the methods and apparatuses hereinmay be configured to reject various types of products, the methods andapparatuses herein are discussed below in the context of manufacturingabsorbent articles. In particular, the methods and apparatuses arediscussed in the context of rejecting advancing, defective diapersduring production.

FIGS. 1 and 2A show an example of a diaper pant 100 that may beassembled and folded in accordance with the apparatuses and methodsdisclosed herein. In particular, FIG. 1 shows a perspective view of adiaper pant 100 in a pre-fastened configuration, and FIG. 2A shows aplan view of the diaper pant 100 with the portion of the diaper thatfaces away from a wearer oriented towards the viewer. The diaper pant100 shown in FIGS. 1 and 2A includes a chassis 102 and a ring-likeelastic belt 104. As discussed below in more detail, a first elasticbelt 106 and a second elastic belt 108 are connected together to formthe ring-like elastic belt 104.

With continued reference to FIG. 2A, the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 119disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 120 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2A is shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 120 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1 and 2A, the diaper pant 100 may include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. The chassis102 may also include an absorbent assembly 140 including an absorbentcore 142 that may be disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2A, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130; a first laterally extending end edge 144 disposed in the firstwaist region 116; and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2A, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 120 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 120 andthe back waist edge 122 of the chassis 102 may encircle a portion of thewaist of the wearer. At the same time, the chassis side edges 128 and130 may encircle at least a portion of the legs of the wearer. And thecrotch region 119 may be generally positioned between the legs of thewearer with the absorbent core 142 extending from the front waist region116 through the crotch region 119 to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, allow the user of the diaper 100 including a chassis 102 havinga particular size before extension to extend the front waist region 116,the back waist region 118, or both waist regions of the diaper 100and/or chassis 102 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper pant 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may be impervious to fluids (e.g.,menses, urine, and/or runny feces) and may be manufactured from a thinplastic film, although other flexible liquid impervious materials mayalso be used. The backsheet 136 may prevent the exudates absorbed andcontained in the absorbent core from wetting articles which contact thediaper 100, such as bedsheets, pajamas and undergarments. The backsheet136 may also comprise a woven or nonwoven material, polymeric films suchas thermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 136 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the diaper pant 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof If the topsheet 138 includes fibers, the fibers may be spunbond,carded, wet-laid, meltblown, hydroentangled, or otherwise processed asis known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2A, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; and4,704,115; and U.S. Patent Publication No. 2009/0312730A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIG. 1.

As previously mentioned, the ring-like elastic belt 104 is defined by afirst elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2A, the first elastic belt 106 defines first and secondopposing end regions 106 a, 106 b and a central region 106 c, and thesecond elastic 108 belt defines first and second opposing end regions108 a, 108 b and a central region 108 c.

The central region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIG. 1, the first end region 106 aof the first elastic belt 106 is connected with the first end region 108a of the second elastic belt 108 at first side seam 178, and the secondend region 106 b of the first elastic belt 106 is connected with thesecond end region 108 b of the second elastic belt 108 at second sideseam 180 to define the ring-like elastic belt 104 as well as the waistopening 110 and leg openings 112.

As shown in FIGS. 2A, 3A, and 3B, the first elastic belt 106 alsodefines an outer lateral edge 107 a and an inner lateral edge 107 b, andthe second elastic belt 108 defines an outer lateral edge 109 a and aninner lateral edge 109 b. The outer lateral edges 107 a, 109 a may alsodefine the front waist edge 120 and the laterally extending back waistedge 122. The first elastic belt and the second elastic belt may alsoeach include an outer, garment facing layer 162 and an inner, wearerfacing layer 164. It is to be appreciated that the first elastic belt106 and the second elastic belt 108 may comprise the same materialsand/or may have the same structure. In some embodiments, the firstelastic belt 106 and the second elastic belt may comprise differentmaterials and/or may have different structures. It should also beappreciated that the first elastic belt 106 and the second elastic belt108 may be constructed from various materials. For example, the firstand second belts may be manufactured from materials such as plasticfilms; apertured plastic films; woven or nonwoven webs of naturalmaterials (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyolefins, polyamides, polyester, polyethylene, or polypropylenefibers) or a combination of natural and/or synthetic fibers; or coatedwoven or nonwoven webs. In some embodiments, the first and secondelastic belts include a nonwoven web of synthetic fibers, and mayinclude a stretchable nonwoven. In other embodiments, the first andsecond elastic belts include an inner hydrophobic, non-stretchablenonwoven material and an outer hydrophobic, non-stretchable nonwovenmaterial.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer layer 162 and the innerlayer 164. The belt elastic material may include one or more elasticelements such as strands, ribbons, or panels extending along the lengthsof the elastic belts. As shown in FIGS. 2A, 3A, and 3B, the belt elasticmaterial may include a plurality of elastic strands 168 which may bereferred to herein as outer, waist elastics 170 and inner, waistelastics 172.

As shown in FIG. 2A, the outer, waist elastics 170 extend continuouslylaterally between the first and second opposing end regions 106 a, 106 band across the central region 106 c of the first elastic belt 106 andbetween the first and second opposing end regions 108 a, 108 b andacross the central region 108 c of the second elastic belt 108. In someembodiments, some elastic strands 168 may be configured withdiscontinuities in areas. For example, as shown in FIG. 2A, the inner,waist elastics 172 extend intermittently along the first and secondelastic belts 106, 108. More particularly, the inner, waist elastics 172extend along the first and second opposing end regions 106 a, 106 b andpartially across the central region 106 c of the first elastic belt 106.The inner, waist elastics 172 also extend along the first and secondopposing end regions 108 a, 108 b and partially across the centralregion 108 c of the second elastic belt 108. As such, the inner, waistelastics 172 do not extend across the entirety of the central regions106 c, 108 c of the first and second elastic belts 106, 108. Thus, someelastic strands 168 may not extend continuously through regions of thefirst and second elastic belts 106, 108 where the first and secondelastic belts 106, 108 overlap the absorbent assembly 140. In someembodiments, some elastic strands 168 may partially extend into regionsof the first and second elastic belts 106, 108 where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, some elastic strands 168 may not extend into anyregion of the first and second elastic belts 106, 108 where the firstand second elastic belts 106, 108 overlap the absorbent assembly 140. Itis to be appreciated that the first and/or second elastic belts 106, 108may be configured with various configurations of discontinuities in theouter, waist elastics 170 and/or the inner, waist elastic elastics 172.

In some embodiments, the elastic strands 168 may be disposed at aconstant interval in the longitudinal direction. In other embodiments,the elastic strands 168 may be disposed at different intervals in thelongitudinal direction. As discussed in more detail below, the beltelastic strands 168, in a stretched condition, may be interposed andjoined between the uncontracted outer layer and the uncontracted innerlayer. When the belt elastic material is relaxed, the belt elasticmaterial returns to an unstretched condition and contracts the outerlayer and the inner layer. The belt elastic material may provide adesired variation of contraction force in the area of the ring-likeelastic belt.

It is to be appreciated that the chassis 102 and elastic belts 106, 108may be configured in different ways other than as depicted in FIG. 2A.For example, FIG. 2B shows a plan view of a diaper pant 100 having thesame components as described above with reference to FIG. 2A, except thefirst laterally extending end edge 144 of the chassis 102 is alignedalong and coincides with the outer lateral edge 107 a of the firstelastic belt 106, and the second laterally extending end edge 146 isaligned along and coincides with the outer lateral edge 109 a of thesecond belt 108.

As previously mentioned, the inspection methods and systems according tothe present disclosure may be utilized during the assembly of variouscomponents of diapers 100. For example, FIG. 4 shows a schematic view ofa converting apparatus 300 adapted to manufacture pant diapers 100. Themethod of operation of the converting apparatus 300 may be describedwith reference to the various components of pant diapers 100 describedabove and shown in FIGS. 1 and 2A. Although the following methods areprovided in the context of the diaper 100 shown in FIGS. 1 and 2A, it isto be appreciated that various embodiments of diapers can bemanufactured according the methods disclosed herein, such as forexample, the absorbent articles disclosed in U.S. Pat. Nos. 7,569,039and 5,745,922; U.S. Patent Publication Nos. 2005/0107764A1,2012/0061016A1, and 2012/0061015A1, which are all hereby incorporated byreference herein.

FIG. 4 shows an example converting apparatus 300 that may operate inconjunction with an inspection system configured to remove defectivearticles from the manufacturing process. The converting apparatusoperates to advance a continuous length of absorbent articles 400including discrete chassis 102 connected with continuous lengths ofadvancing first and second elastic belt substrates 402, 404 along amachine direction MD. As discussed in more detail below, portions of thefirst belt substrate may be converted to correspond with the firstelastic belt 106 and portions of the second belt substrate may beconverted to correspond with the second elastic belt 108 discussed abovewith reference to FIGS. 1-3B. As shown in FIGS. 4 and 5A, the first beltsubstrate 402 includes a first, garment facing, surface 402 a and anopposing second, wearer facing, surface 402 b. And the second beltsubstrate 404 a first, garment facing, surface 404 a and an opposingsecond, wearer facing, surface 404 b. The lateral axis of each chassis102 is parallel with the machine direction MD, and the longitudinal axisof each chassis is perpendicular with the machine direction MD. Thechassis 102 are also spaced apart from each other along the machinedirection. Opposing waist regions 116, 118 of the spaced apart chassis102 are connected with continuous lengths of advancing first and secondelastic belt substrates 402, 404.

It is to be appreciated that FIG. 4 illustrates an example a downstreamportion of a converting process configured to assemble a continuouslength of absorbent articles by combining various continuous substratesand/or discrete components with each other. It is to be appreciated theapparatus of FIG. 4 can be configured to work with variousconfigurations of converting systems, such as for example thosedisclosed in U.S. patent application Ser. No. 13/434,984, entitled“Apparatuses and Methods for Making Absorbent Articles,” filed on Mar.30, 2012, further identified by Attorney Docket No. 12390.

As shown in FIGS. 4 and 5A, the continuous length of absorbent articles400 advances to a folding apparatus 302. At the folding apparatus 302,each chassis 102 is folded in the cross direction CD along a lateralaxis 126 to place the first waist region 116, and specifically, theinner, body facing surface 132 into a facing, surface to surfaceorientation with the inner, body surface 132 of the second waist region118. The folding of the chassis 102 also positions the wearer facingsurface 402 b of the first belt substrate 402 extending between eachchassis 102 in a facing relationship with the wearer facing surface 404b of the second belt substrate 404 extending between each chassis 102.

As shown in FIGS. 4 and 5B, the folded discrete chassis 102 connectedwith the first and second belt substrates 402, 404 are advanced from thefolding apparatus 302 to a bonder 304. The bonder 304 operates to bond aportion of the second belt substrate 404 extending between each chassis102 with a portion of the first belt substrate 402 extending betweeneach chassis 102, thus creating discrete bond regions 406. It is to beappreciated that various types of bonder apparatuses and methods can beused to bond the second belt substrate material 404 with the first beltsubstrate material 402, such as for example disclosed in U.S. Pat. Nos.6,248,195; 6,546,987; and 7,383,865, as well as U.S. Patent PublicationNo. 2012/0021186A1, which are incorporated by reference herein.

With continued reference to FIG. 4, the continuous length of absorbentarticles 400 are advanced from the bonder 304 to a cutting apparatus 306including a knife roll 308 and anvil roll 310. The cutting apparatuscuts the discrete bond regions 406 are cut along the cross direction CDto create a first side seam 178 on an absorbent article 100 and a secondside seam 180 on a subsequently advancing absorbent article. As such,the elastic belt substrates 402, 404 are cut along the seams 406 tocreate discrete diapers 100, such as shown in FIG. 1. As shown in FIG.4, the apparatus 300 may include opposing first and second beltconveyors 312, 314 that help hold the continuous length of absorbentarticles 400 in position while advancing to the cutting apparatus 306.

From the cutting apparatus 306, a first carrier 316 may advance thediscrete diapers 100 in the machine direction MD in a first orientationto a transfer apparatus 320. With continued reference to FIGS. 4 and 5C,the discrete diapers 100 are transferred from the first carrier 316 in afirst orientation to the transfer apparatus 320. In turn, the transferapparatus 320 moves the discrete diapers 100 in the first orientationfrom the first carrier 316, orients the diapers 100 into a secondorientation, and transfers the articles 100 to a second carrier 322 inthe second orientation, such as shown in FIG. 5D. From the secondcarrier 322, the discrete diapers 100 may be subjected to furtherprocessing steps, such as for example, side panel tucking and/orpackaging operations.

As discussed above, the converting apparatus 300 may be configured toconstruct and arrange the discrete diapers 100 in various positions ororientations before being transferred to the transfer apparatus 320, andas such, various representations of first orientations may be describedin various ways. For example, as shown in FIG. 5C, the advancingdiscrete diapers 100 are shown in a first orientation wherein thelongitudinal axis 124 of each absorbent article 100 is oriented in across direction CD. In FIG. 5C, the first orientation may also bedescribed as having the longitudinal axis 124 perpendicular or generallyperpendicular to the machine direction MD. The discrete articles 100 aretransferred to the transfer apparatus 320 and then transferred to asecond carrier 322 in a second orientation. As discussed above withreference to the first orientation, the second orientation may bedescribed in various ways. For example, as shown in FIG. 5D, theadvancing discrete diapers 100 are shown in a second orientation whereinthe longitudinal axis 124 of each advancing absorbent article 100 isoriented so as to be parallel or generally parallel with the machinedirection MD. The second orientation may also be described withreference to the first orientation. For example, the diapers 100 in thesecond orientation may be described as having been turned by an anglerelative to the diapers 100 in the first orientation, such as 90°.

It is to be appreciated that various components of the convertingapparatus 300 have various configurations. For example, although thefirst carrier 316 and the second carrier are depicted as belt conveyorsin FIG. 4, it is to be appreciated that the first carrier 316 and/or thesecond carrier 322 may be configured in various ways. For example, insome embodiments, the first carrier 316 and/or second carrier 322 may beconfigured as a rotating drum. In order to help mitigate problemsassociated with uncontrolled movement of the discrete diapers 100 duringconveyance, the first carrier 316 and/or second carrier 322 may alsoinclude a vacuum system in communication with a porous and/or aperturedbelt or other foraminous carrier surface 317, 323 that allows thesuction force of the vacuum system to be exerted on diapers 100. Asdiscussed below with reference to FIG. 6, a pneumatic system 500,including a vacuum system 502 and a positive pressure system 504, may befluidly connected with the porous and/or apertured carrier surface 317of the first carrier 322. The vacuum system 502 may operate to apply asuction force to help hold the discrete diapers 100 on the carriersurface 317, and the positive pressure system 504 may operate to applypositive pressure force to blow-off or push the discrete diapers 504away from the carrier surface 317. As discussed in more detail below,the pneumatic system 500 may also be adapted to work with an inspectionsystem to remove defective diapers 100R from the converting process.Referring back to FIG. 4, a belt conveyor 318 may also be positionedadjacent the first carrier 316 to help hold the discrete diapers 100flat against the first carrier 316.

As shown in FIG. 4, the transfer apparatus 320 may include one or morecarrier members 324 connected with support members 326 and adapted torotate or orbit about a first axis of rotation 328. For example, thetransfer apparatus 320 embodiment shown in FIG. 4 rotates clockwisearound the first axis of rotation 328. The carrier members 324 may beadapted to pivot about a second axis 330 while moving or orbiting froman article pick-up zone 332 adjacent the first carrier 316 to an articledrop-off zone 334 adjacent the second carrier 322. As such, eachadvancing discrete diaper 100 may be transferred in the pick-up zone 332from the first carrier 316 in a first orientation to a carrier member324. More particularly, the diaper 100 may be transferred onto a carriersurface 325 of the carrier member 324. As the transfer apparatus 320rotates, the carrier member 324 and the diaper 100 move from the pick-upzone 332. As the carrier member 324 moves from the pick-zone to orbitaround the first axis of rotation 328, the carrier member 324 pivotsaround the second axis 330 to orient the diaper 100 into the secondorientation. It is to be appreciated that the carrier member 324 maypivot by various degrees of rotation around the second axis 330, such asfor example 90° or 180°, while moving from the pick-up zone 332 to thedrop-off zone 334. The carrier member 324 continues to orbit around thefirst axis of rotation 328 and the diaper 100 is transferred to thesecond carrier 322 in the drop-off zone 334 in the second orientation.

It is to be appreciated that various transfer apparatus configurationsmay utilized, such as for examples, the transfer apparatuses disclosedin U.S. patent application Ser. No. 13/447,531; U.S. Pat. Nos.4,578,133; 4,617,082; 6,319,347; 7,341,047; 7,587,966; and 8,011,493;European Patent Publications EP0812789A2; EP1179495A1; and EP1820757A1;and European Patent Application No. EP12162251.8. It is also to beappreciated that the transfer apparatus 320 can be configured toincrease or decrease the speed and/or spacing of the articles travelingfrom the first carrier 316 to the second carrier 322. It is also to beappreciated that in some embodiments, the carrier member 324 may notpivot about the second axis 324.

As discussed below with reference to FIG. 6, a pneumatic system 550,including a vacuum system 552 and a positive pressure system 554, may befluidly connected with a porous and/or apertured carrier surface 325 ofeach carrier member 324. The vacuum system 552 may operate to apply asuction force to help hold the discrete diapers 100 on the carriersurface 552, and the positive pressure system 554 may operate to apply apositive pressure force to blow-off or push the discrete diapers 554away from the carrier surface 325. As such, the vacuum system 552 mayapply a suction force against the diapers 100 in a radially inwarddirection relative to the first axis of rotation 328, and the positivepressure system 552 may apply a pushing or blow-off force in a radiallyoutward direction relative to the first axis of rotation 328. In someembodiments, the vacuum system 552 may be configured to apply a suctionforce to the diapers 100 in the pick-up zone 332 and cease applying thesuction force to the diapers 100 in the drop-off zone 334. In someconfigurations, the positive pressure system may be operated at thedrop-off zone 334 to apply a pushing or blow-off force to help removethe diapers 100 from carrier surface 325 of the carrier members 324. Asdiscussed in more detail below, the pneumatic system 550 may also beadapted to work with an inspection system to remove defective diapers100R from the carrier members 324 before being carried to the drop-offzone 334.

As previously mentioned, the first carrier 316 may include a porousand/or apertured carrier surface 317, and each carrier member 324 mayinclude a porous and/or apertured carrier surface 325. For example, theembodiment of the first carrier 316 shown in FIGS. 7A-8B has a carriersurface 317 that may include a plurality of apertures 319. And theembodiment of the carrier member 324 shown in FIGS. 10A-11 has a carriersurface 325 that may include a plurality of apertures 321. As previouslymentioned, the apparatus 300 may include a pneumatic system 500 in fluidcommunication with the carrier surface 317 of the first carrier 316,and/or a pneumatic system 550 in fluid communication with the porousand/or apertured carrier surface 325 of each carrier member 324 on thetransfer apparatus 320. As such, it is to be appreciated that varioustypes of pneumatic configurations may be used to selectively applyvacuum pressure and/or air pressure to the first carrier 316 and/or thecarrier members 324.

For example, FIG. 6 provides a schematic illustration of a pneumaticsystem 500 fluidly connected with the first carrier 316. The pneumaticsystem 500 includes a vacuum system 502 and a positive pressure system504. The vacuum system 502 is configured to create a vacuum pressure(−p) that is less than atmospheric pressure. As such, when the vacuumsystem 502 is fluidly connected with the carrier surface 317 of thefirst carrier 316, air A is drawn toward and through the apertures 319in the carrier surface 317 such as shown in FIGS. 7A and 8A, creating asuction force that helps hold diapers 100 onto the carrier surface 317.The positive pressure system 504 is configured to create a positivepressure (+p) that is greater than atmospheric pressure. As such, whenthe positive pressure system 504 is fluidly connected with the carriersurface 317 of the first carrier 316, air A is forced through and fromthe apertures 319 in the carrier surface 317 such as shown in FIGS. 7Band 8B, creating a pushing or blow-off force that helps push the diapers100 away from the carrier surface 317.

In the configuration shown in FIG. 6, the vacuum system 502 isconfigured to provide a continuous suction pressure to a first zone orlength 317 a of the carrier surface 317 of the first carrier 316. Thevacuum system 502 and pressure system 504 are also connected with arotary valve assembly 506 that is operable to fluidly connect the vacuumsystem 502 or the pressure system 504 with a second zone or length 317 bof the carrier surface 317 of the first carrier 316. Although a rotaryvalve assembly configuration is discussed herein, it is to beappreciated that various types of valve configurations can be used. Thefirst zone 317 a may be upstream of the second zone 317 b, and thesecond zone 317 b may be downstream of the first zone 317 a. Further,the transition from the first zone 317 a to the second zone 317 b may bein the pick-up zone 332, upstream of the pick-up zone 332, or downstreamof the pick-up zone 332. As shown in FIGS. 7A-8B, the valve assembly 506may include a valve body 508 having an opening 510 fluidly connectedwith the carrier surface 317 of the first carrier 316. The valve body508 is also fluidly connected with the vacuum system 502 and thepositive pressure system 504. The valve body 508 houses a valve insert512 having a first chamber 514 and a second chamber 516 separated fromeach other by a wall 518. The first chamber 514 may include a first port520 and a second port 522, and the second chamber 516 may include afirst port 524 and a second port 526.

As shown in FIGS. 7A-8B, the valve insert 512 may be connected with anactuator 528 adapted to rotate or pivot the valve insert 512 inside thevalve body 508 to selectively place the vacuum system 502 and thepressure system 504 in fluid communication with the carrier surface 317of the first carrier 316. For example, the actuator 528 may rotate thevalve insert 512 to a first position such as shown in FIGS. 7A and 8A toplace the vacuum system 502 in fluid communication with the carriersurface 317 of the first carrier 316. When the valve insert 512 isplaced in the first position, the pneumatic system 500 is in a firstmode of operation wherein the vacuum system 502 is in fluidcommunication with the carrier surface 317 along the first zone 317 aand the second zone 317 b. More particularly, as shown in FIGS. 7A and8A, the first port 520 of the first chamber 514 is placed in fluidcommunication with the vacuum system 502, and the second port 522 of thefirst chamber 514 is placed in fluid communication with the opening 510in the valve body 508. Thus, in the first position, the vacuum system502 draws air A toward and through apertures 319 in the carrier surface317, through opening 510 in the valve body 508, and through the secondport 522 into the first chamber 514. The air is also drawn from thefirst chamber 514 through the first port 520 and to the vacuum system502. As the vacuum system draws air into the apertures 319 in thecarrier surface 317, a suction force is created that helps hold diapers100 in position on the carrier surface 317.

It is to be appreciated that actuator 528 may be configured in variousways. For example, in some embodiments, the actuator 528 may be providedin the form an electromechanical solenoid; servomotor; pneumaticcylinder; or hydraulic cylinder and may include linkage mechanisms, suchas gears, to redirect output motion of the actuator in line with therequired direction of motion of the valve insert.

As shown in FIGS. 7B and 8B, the actuator 528 may also rotate the valveinsert 512 to a second position to place the positive pressure system504 in fluid communication with the carrier surface 317 of the firstcarrier 316. When the valve insert 512 is placed in the second position,the pneumatic system 500 is in a second mode of operation wherein thevacuum system 502 is in fluid communication with the carrier surface 317along the first zone 317 a, and the positive pressure system 504 is influid communication with the second zone 317 b. More particularly, asshown in FIGS. 7B and 8B, the first port 524 of the second chamber 516is placed in fluid communication with the vacuum system 502, and thesecond port 526 of the second chamber 516 is placed in fluidcommunication with the opening 510 in the valve body 508. Thus, in thesecond position, the positive pressure system 504 forces air throughfirst port 524 and into the second chamber 516 of the valve insert 512.From the second chamber 516, the air A is forced through the second port526, through the opening 510 in the valve body 508; and through and awayfrom the carrier surface 317. As the positive pressure system forces airthrough the carrier surface 317, a blow-off or pushing force is createdaway from the carrier surface 317 that helps remove diapers 100 from thecarrier surface 317. As discussed below, the actuator 528 may beoperably connected with an inspection system to rotate the valve insert512 to the first position shown in FIGS. 7A and 8A in response to areject command from the inspection system to remove defective diapers100R from the converting process.

FIG. 6 also provides a schematic illustration of a pneumatic system 550operably connected with the carrier members 324 of the transferapparatus 320. The pneumatic system 550 includes a vacuum system 552 anda positive pressure system 554. The vacuum system 552 is configured tocreate a vacuum pressure (−p) that is less than atmospheric pressure. Assuch, when the vacuum system 552 is fluidly connected with the carriersurface 325 of the carrier member 324, air A is drawn toward and throughapertures 321 in the carrier surface 325 such as shown in FIGS. 10A and11, creating a suction force that helps hold diapers 100 onto the poroussurface 325. The positive pressure system 554 is configured to create apositive pressure (+p) that is greater than atmospheric pressure. Assuch, when the positive pressure system 554 is fluidly connected withthe porous surface 325 of the carrier member 324, air A is forcedthrough and from apertures 321 in the carrier surface 325 such as shownin FIG. 10B, creating a pushing or blow-off force that helps push thediapers 100 away from the carrier member 324.

In the configuration shown in FIG. 6, the vacuum system 552 and thepressure system 554 are connected with a manifold valve assembly 556that is operable to selectively fluidly connect the vacuum system 552 orthe pressure system 554 with the carrier surfaces 325 of carrier members324 over a first portion 558 of the orbital path defined by the carriermembers 324 around the first axis of rotation 328. The vacuum system 552is also configured to provide a continuous suction pressure to thecarrier surfaces 325 of carrier members 324 over a second portion 560 ofthe orbital path defined by the carrier members 324 around the firstaxis of rotation 328.

As shown in FIGS. 6-11, the support members 326 of the transferapparatus 320 may extend radially outward from a rotor member 327adapted to rotate around the first axis of rotation 328. The supportmembers 324 may also include openings 329 in fluid communication withthe carrier surfaces 325 of the carrier members 324. As such, air A canflow in and out of apertures 321 in the carrier surface 325, through thesupport member 326, and in and out of the opening 329, such as shown inFIGS. 10A and 10B. As discussed below, as the rotor member 327 rotatesaround the first axis of rotation 328, the openings 329 may be placed influid communication through a stator member, referred to herein as amanifold stator 562, with vacuum system 552 and/or positive pressuresystem 554 in the first zone 558 and second zone 560.

As shown in FIGS. 9-11, the manifold stator 562 is stationary and ispositioned adjacent the rotor member 562. The manifold stator 562includes an arcuate manifold 564 that is fluidly connected with theopenings 329 of the support members 326 as the rotor member 562 rotatesthe support members 326 and associated carrier members through the firstzone 558 and second zone 560. The manifold stator is also operablyconnected with the manifold valve assembly 556. More particularly, themanifold valve assembly 556 includes a manifold insert 566 connectedwith an actuator 568. The manifold insert 566 is arcuately shaped andextends along and inside a portion of the length of the manifold 564.And the manifold insert is movably and/or slidably connected with themanifold 564. The actuator 568 selectively moves the manifold insert 566back and forth between first and second positions, V and P,respectively, within the manifold 564, as shown in FIGS. 10A and 10B. Asshown in FIG. 9, the portion of the manifold 564 housing the manifoldinsert 566 corresponds with the first zone 558, and the remainingportion of the manifold 564 that does not house the manifold insert 566corresponds with the second zone 560.

It is to be appreciated that actuator 568 may be configured in variousways. For example, in some embodiments, the actuator 568 may be providedin the form an electromechanical solenoid; servomotor; pneumaticcylinder; or hydraulic cylinder and may include linkage mechanisms, suchas gears, to redirect output motion of the actuator in line with therequired direction of motion of the valve insert.

With continued reference to FIGS. 9-11, the positive pressure system 554is fluidly connected with the manifold stator 562 through a first port570, and the vacuum system 552 is fluidly connected with the manifoldstator 562 through a second port 572. The actuator 568 moves themanifold insert 566 back and forth to selectively place the positivepressure system 554 in fluid communication with a portion of themanifold 564 corresponding with the first zone 558. More particularly,the manifold insert includes an opening 574 that is selectively placedin fluid communication with the first port 570 in the manifold stator562 depending on the position of the manifold insert 566. For example,in FIG. 10A, the actuator 568 has moved the manifold insert 566 into afirst position V. In position V, the manifold insert 566 covers orblocks the first port 570. In contrast, as shown in FIG. 10B, theactuator 568 has moved the manifold 566 into a second position P. Inposition P, the manifold insert 566 does not block the first port 570.As such, pressurized air can flow from the positive pressure system 554through the first port 570 and the opening 574 in the manifold insertand into a portion of the manifold 564 corresponding with arcuate lengthof the manifold insert 566. As shown in FIGS. 9 and 11, the vacuumsystem 552 provides a continuous vacuum pressure (−p) to the portion ofthe manifold 564 that does not house the manifold insert 566. And whenthe manifold insert 566 is in position V, such as shown in FIG. 10B, thevacuum system 552 provides a vacuum pressure (−p) to the portion of themanifold 564 that houses the manifold insert 566.

Although the actuator 568 is described above as moving the manifoldinsert 566 back and forth to selectively place the positive pressuresystem 554 in fluid communication with a portion of the manifold 564corresponding with the first zone 558, it is to be appreciated thatadditional configurations are contemplated. For example, the actuator568 may be configured to move the manifold insert 566 to block the fluidcommunication of the vacuum system 552 with a portion of the manifold564, and a solenoid may be used to selectively place the positivepressure system 554 in fluid communication with a portion of themanifold 564.

As shown in FIGS. 9, 10A, and 11, when the manifold insert 566 is inposition V, the vacuum system applies a suction pressure along theentire length of the manifold 564, including the first zone 558 and thesecond zone 560. As the rotor member 327 rotates and moves the openings329 in the support members 326 along the length of the manifold 564, thevacuum system 552 draws air A into apertures 321 in the carrier surface325 of the carrier member 324, through the support member 326 andmanifold 324, and from the second port 572 in the manifold stator 562.As such, the pneumatic system 550 may be placed in a first mode ofoperation when the manifold insert 566 is in position V, wherein thevacuum system 552 applies a suction force to help hold diapers 100 onthe carrier members 324 through the first zone 558 and the second zone560.

As shown in FIGS. 9, 10B, and 11, when the manifold insert 566 is inposition P, positive pressure system 554 applies a positive pressure(+p) along the length of the manifold 546 corresponding with the firstzone 558. And the vacuum system applies a suction pressure (−p) alongthe length of the manifold 564 corresponding with the second zone 560.Thus, as the rotor member 327 rotates and moves the openings 329 in thesupport members 326 along the length of the manifold 564 correspondingwith the first zone 558, the positive pressure system 554 forces air toflow into the first port 570 in the manifold stator 562, through theopening 574 in the manifold insert 566, into the portion of the manifold564 corresponding with the first zone 558. Pressurized air then flowsfrom the manifold through the support member 326 and air A exits fromapertures 321 in the carrier surface 325 of the carrier member 324. Assuch, the pneumatic system 550 may be placed in a second mode ofoperation when the manifold insert 566 is in position P, wherein thepositive pressure system 554 applies a blow-off or pushing force to helppush diapers 100 away from the carrier members 324 in the first zone558.

As discussed below, the actuator 568 may be operably connected with aninspection system to move the manifold insert 566 into position P inresponse to a reject command from the inspection system to removedefective diapers 100R from the converting process.

As previously mentioned, the methods and apparatuses 300 herein may alsoutilize inspection systems and processes for detecting and monitoringdefective absorbent articles 100 during the manufacturing process. Anembodiment of an inspection system 600 is schematically represented inFIG. 4. As discussed in more detail below, the inspection systems andmethods may utilize feedback from technologies, such as vision systems,sensors, communication networks, and controllers. In some embodiments,the inspection systems may be configured to alarm and/or recordoccurrences of defective products during the manufacturing processes aswell as remove defective products from the manufacturing process.

In some embodiments, the inspection system 600 may detect and/or trackmissing or defective components and/or substrates through themanufacturing process. The inspection system 600 may also correlateinspection results from such defective components and/or substrates toabsorbent articles 100 made therefrom. In turn, the inspection system600 may be used to control a pneumatic system on the carrier apparatus320, wherein defective absorbent articles 100R are rejected. In someconfigurations, defective articles 100R may be removed from the process,such as shown in FIG. 4, wherein defective diapers 100R are removed fromcarrier members 324 while traveling from the pick-up zone 332 anddirected a reject bin 336. Diapers 100 that are not deemed to bedefective may be transferred to the drop-off zone 332 and subject tofurther processing steps.

It is to be appreciated that the term “reject bin” is used hereingenerically to designate the location where rejected diapers may beconveyed. As such, the reject bin 336 may include various systems. Forexample, the reject bin may 336 may include systems such as conveyorsand/or pneumatic systems to provide additional transport or conveyanceof rejected diapers to other locations.

As shown in FIG. 4, the inspection system 600 may include a sensor 602operatively connected with a controller 604. Various types of sensors602 and other devices may be arranged adjacent the apparatus 300 and maycommunicate with the controller 604. Based on such communications, thecontroller 604 may monitor and affect various operations on theapparatus 300. As discussed in more detail below, for example, thecontroller 604 may send reject commands 1000 to affect operation of thepneumatic system 500 operably connected with the first carrier 316and/or the pneumatic system 550 operably connected with the transferapparatus 320 based on communications with the sensor 602.

It is to be appreciated that various types of controller and sensorconfigurations may be utilized with the inspection system 600, such asfor example, disclosed in U.S. Pat. No. 8,145,338. For example, thecontroller 604 may include a computer system, which may, for example,include one or more types of programmable logic controller (PLC) and/orpersonal computer (PC) running software and adapted to communicate on anEthernetIP network. Some embodiments may utilize industrial programmablecontrollers such as the Siemens S7 series, Rockwell ControlLogix, SLC orPLC 5 series, or Mitsubishi Q series. The aforementioned embodiments mayuse a personal computer or server running a control algorithm such asRockwell SoftLogix or National Instruments Labview or may be any otherdevice capable of receiving inputs from sensors, performing calculationsbased on such inputs and generating control actions through servomotorcontrols, electrical actuators or electro-pneumatic, electrohydraulic,and other actuators.

It is to be appreciated that various different types of inspectionsensors 602 may be used to monitor substrates and various components.For example, inspection sensors 602 may be configured as photo-opticsensors that receive either reflected or transmitted light and serve todetermine the presence or absence of a specific material;metal-proximity sensors that use electromagnetic to determine thepresence or absence of a ferromagnetic material; or capacitive or otherproximity sensors using any of a number of varied technologies todetermine the presence or absence materials. Inspection sensors 602 mayalso be configured as vision systems and other sub-processing devices toperform detection and, in some cases, logic to more accurately determinethe status of an inspected product. Particular examples of suchinspections sensors 602 may include Cognex Insight, DVT Legend orKeyence smart cameras, component vision systems such as NationalInstruments PXI or PC based vision system such as Cognex VisionPro orany other vision system software which can run on a PC platform.

As previously mentioned, the inspection sensors 602 may detect missing,misplaced, and/or defective and/or damaged components and/or substratesused in assembling absorbent articles 100. It is also to be appreciatedthat the inspection sensors 602 may be configured to perform variousfunctions in the inspection system 600. For example, the sensors may beconfigured to detect defects within substrates and/or componentsthemselves, such as for example, damage, holes, tears, dirt, and thelike, and may also detect defective assemblies and/or combinations ofthe substrates and components, such as for example, missing and/ormisplaced elastic material and the like. As such, inspection sensors maybe configured to detect the presence or absence of substrates and/orcomponents, and may be configured to detect the relative placement ofsubstrates and/or components. As discussed in more detail below, basedon the detections of the inspection sensors 602, feedback signals fromthe inspection sensors in the form of inspection parameters 1000 arecommunicated to the controller 604.

It should also be appreciated that inspection parameters 1000 may beprovided from inspection sensors 602 in various forms. In someconfigurations, inspection parameters 1000 may be in the form of“results,” such as for example, provided from a sensor state changeresulting in a binary input corresponding with the detected presence orabsence of a defect, such as for example, the presence or absence ofcomponents and/or substrates. For example, inspection parameters 1000may indicate the presence or absence of discrete bond regions 406; andside seams 178, 180. In other examples, an inspection parameter 1000 mayindicate the presence or absence of a tear, hole, splice tape, and/orcontaminants in the first and second elastic belt substrates 402, 404and/or chassis 102.

In still other examples, the inspection sensors 602 may be configured todetect improperly cut and/or uncut absorbent articles 100. For example,in some configurations, inspection sensors 602 may include a proximitysensor that detects the position of a loading system, such as an aircylinder, for the cutting apparatus 306. Such a proximity sensor may beconfigured to detect various operating conditions with respect to thecutting apparatus 306, such as for example, an operating condition thatresults from the knife roll 308 being unexpectedly unloaded. Such acondition may be caused, for example, by a misplaced absorbent core 142that advances between the knife roll 308 and anvil roll 310 that causesthe knife roll 308 to be displaced from the anvil roll 310. As a resultof the knife roll displacement, some absorbent articles 100 may not becut or may be improperly cut by the cutting apparatus 306. Thus,feedback from the proximity sensor could be used by the inspectionsystem 500 to issue a reject command and prevent the transfer apparatus320 from transferring the uncut and/or improperly cut absorbent articles100R without having to stop the entire converting process to remove thedefective articles.

In some embodiments, inspection parameters 1000 may be provided in theform of measurements and/or numerical indications of detected positionsof elastic material and/or substrates; numerical indications of thepositions of elastic material and/or substrates relative to otherelastic materials and/or substrates; and/or numerical indications of thepositions of elastic materials and/or substrates relative to anotherphysical or virtual reference. For example, inspection parameters 1000may indicate the relative position of one feature of an absorbentarticle, such as an outer lateral edge 107 a, 109 a of an elastic belt106, 108, with respect to an elastic strand 168. In other embodiments,inspection parameters 1000 may be in the form of images transferred viaa standard protocol such as ftp (File Transfer Protocol), DDE (DynamicData Exchange), or OPC (Object Linking and Embedding for ProcessControl), which are stored in a database or stored in a specifieddirectory on an image server for the purpose of either operatorvisualization, offline image processing or claim support.

As shown in FIG. 4, the inspection sensors 602 may be connected with thecontroller 604 through a communication network 606, which allows theinspection sensors 602 to communicate inspection parameters 1000 to thecontroller 604. The inspection sensors 602 and the controller 604 may beconnected directly with the communication network 606. Such sensors mayinclude, for example, vision systems such as National Instruments CVS orany PC-based vision system such as Cognex VisionPro. Such sensors mayalso include other controllers that may be configured as peers to thecontroller or may be configured as subordinate to the controller. Insome embodiments, the inspection sensors 602 may be indirectly connectedwith the communication network 606. For example, the inspections sensors602 may be connected with the communication network 606 through a remoteinput and output (I/O) station, such as discussed in U.S. PatentPublication No. 2010/0305740A1. When utilizing remote I/O stations, theinspection sensors 602 may be hardwired to the remote I/O stations, andin turn, the remote I/O stations may be connected with the communicationnetwork 606. Example remote I/O stations or other IEEE-1588 basedinstruments that can be utilized with systems and methods hereininclude, for example a National Instruments PCI-1588 Interface (IEEE1588 Precision Time Protocol Synchronization Interface) thatsynchronizes PXI systems, I/O modules and instrumentation overEthernet/IP or a Beckhoff Automation EtherCat and XFC technology(eXtreme Fast Control Technology).

In some embodiments, the inspection sensors 602 may communicateinspection parameters 1002 to the controller 604. In some instances, theinspection parameter 1002 may provide an indication of a defect in asubstrate and/or component and/or defective assemblies and/orcombinations of the substrates and components used to make absorbentarticles 100. It is to be appreciated that the inspection system 600 mayinclude inspection sensors 602 that monitor various locations of themanufacturing process in addition to the locations shown in FIG. 4. Thedetected defect may be tracked during the manufacturing process andcorrelated with a defective absorbent article 100R. In turn, thecontroller 604 of the inspection system 600 may send a reject command1000 to one or more components of the converting apparatus 300, such asone or more pneumatic systems 500, 550, to remove the defective article100R from the manufacturing process.

As previously mentioned, the inspection system 600 may be utilized withthe apparatuses and methods 300 herein to detect and monitor defectsduring the manufacturing process. For example, as shown in FIG. 4, thesensor 602 monitors the continuous length of absorbent articles 400advancing from the bonder 304. As such, the sensor 602, 602 a in FIG. 4may be configured to inspect and/or detect the quality and/or locationsof the discrete bond regions 406, such as shown in FIG. 5B. Inspectionsensors 602, 602 b may also be located between the cutting apparatus 306and the transfer apparatus 320. As such, the sensors 602 may beconfigured to monitor components and substrates combined to create thecontinuous length of absorbent articles 400 in various stages of theassembly process and/or monitor the quality and/or location of the cutsmade by the cutting apparatus 306.

With continued reference to FIG. 4, the inspection system 600 may alsocorrelate inspection results and measurements from defective substratesand components to defective absorbent articles 100R made therefrom. Inturn, the inspection system 600 may be used to control an apparatus orsystem, wherein defective absorbent articles 100R are rejected. In someconfigurations, the controller 604 of the inspection system 600 may senda reject command 1000 to the pneumatic system 500 operably connectedwith the first carrier 316 and/or the pneumatic system 550 operablyconnected with the transfer apparatus 320, which in turn, removesdefective articles 100R from the process, such as shown in FIG. 4. Insome embodiments, defective diapers 100R may be redirected from themanufacturing process to a reject bin 336. Diapers 100 that are notdeemed to be defective may be subject to further processing steps, suchas folding and packaging.

It is to be appreciated that the inspection system 600 may operate inconjunction with elements of the converting apparatus 300 in variousways. For example, various components of the pneumatic systems 500, 550,first carrier 316, and/or transfer apparatus 320 may be adapted tooperate in various ways in response to a reject command 1000 to removedefective diapers 100R from the manufacturing process.

As discussed above, absorbent articles 100 may be transferred from thefirst carrier 316 to a carrier member 324 on the transfer apparatus 320.A pneumatic system 550 including a vacuum system 552 and a positivepressure system 554 may also be operably connected with the transferapparatus 320 as described above with reference to FIGS. 6 and 9-11. Assuch, in a first mode of operation, the vacuum system 552 exerts asuction force to help hold the diapers 100 in position on the carriermembers 324 while moving from the pick-up zone 332, through the firstzone 558 and second zone 560, and to the drop-off zone 334. In someembodiments, a reject command 1000 may be operable place the pneumaticsystem in a second mode of operation, such as for example, by operatingthe actuator 568 to move the manifold insert 566 into position P. Assuch, the positive pressure system 554 applies a blow-off or pushingforce to help push the defective diapers 100R away from the carriermembers 324 in the pick-up zone 332 and/or first zone 558. After thedefective diapers 100R are rejected, the inspection system 600 may thenreturn the pneumatic system to the first mode of operation. It is to beappreciated the inspection system 600 and pneumatic system 550 may beoperable to reject defective diapers 100R by placing the pneumaticsystem 550 into the second mode of operation before the defectivediapers 100R are transferred to the carrier members 324 in the pick-upzone 332. Thus, positive pressure system 554 may prevent defectivediapers 100R from being transferred to the carrier member 324, and mayinstead be forced away from the transfer apparatus 320 toward the rejectbin 336. In some embodiments, the inspection system 600 and pneumaticsystem 550 may be operable to reject defective diapers 100R by placingthe pneumatic system 550 into the second mode of operation after thedefective diapers 100R are transferred to the carrier members 324 in thepick-up zone 332. Thus, positive pressure system 554 remove defectivediapers 100R the carrier member 324 in for example, the first zone 558,and may be directed away from the transfer apparatus 320 toward thereject bin 336.

In some embodiments, the pneumatic system 550 may not include a positivepressure system 554. As such, a reject command 1000 may be operable toonly prevent the vacuum system from applying a suction force todefective diapers 100R in the pick-up zone 332. Thus, defective diapers100R may not be transferred to the carrier member 324, and may insteadfall away from the transfer apparatus 320 toward the reject bin 336. Insome embodiments, in response to a reject command 1000, the vacuumsystem may be adapted to cease applying a suction force to a defectivediaper 100R that has been picked up by a carrier member 324 before beingtransferred to the drop-off zone 334. As such, the defective diaper 100Ris no longer held to the carrier member 324 by the vacuum system.Centrifugal force resulting from the rotational motion of the transferapparatus 320 may separate the defective diaper 100R from the movingcarrier member 324.

In some embodiments, a pneumatic system 500 including a vacuum system502 and a positive pressure system 504 may also be operably connectedwith the first carrier 316 as described above with reference to FIGS.6-8B. In the second mode of operation discussed above with reference toFIGS. 4, 6, 7B and 8B, the vacuum system 502 is in fluid communicationwith the carrier surface 317 along the first zone 317 a, and thepositive pressure system 504 is in fluid communication with the secondzone 317 b. The transition from the first zone 317 a to the second zone317 b may be located in the pick-up zone 332. As such, the vacuum system502 applies a suction force to the diapers 100 to help hold the diapers100 on the carrier surface 317 of the first carrier 316 while advancingto the pick-up zone 332. While advancing to the second zone 317 b at thepick-up zone 334, the positive pressure system 504 may apply a blow-offforce to push the diapers 100 away from the carrier surface 317 of thefirst carrier 316 and toward a carrier member 324 moving through pick-upzone 334.

In some embodiments, a reject command 1000 may be operable place thepneumatic system 500 in the first mode of operation discussed above withreference to FIGS. 4, 6, 7A, and 8A, such as for example, by operatingthe actuator 528 to rotate the valve insert 566 into the first position.Thus, is the first mode of operation, the vacuum system 502 is in fluidcommunication with the carrier surface 317 along the first zone 317 aand second zone 317 b. As such, the vacuum system 502 applies a suctionforce to hold the defective diaper 100R on the first carrier 316 as thediaper 100R advances past the pick-up zone and into the second zone 317b. Thus, a reject command 1000 may be configured to be operable tomaintain suction pressure to hold the defective diaper 100R on the firstcarrier 316, allowing the first carrier 316 to advance the defectivediaper 100R past the pick-up zone 332. Once past the pick-up zone, thereject command 1000 may be operable to place the pneumatic system backinto the second mode of operation, reengaging the positive pressuresystem 504, to blow or push the defective diaper away from the carriersurface 317 of the first carrier 316 in the second zone 317 b toward thereject bin 336. In some embodiments, the defective diaper 100R is heldto the first carrier 316 by suction forces until advance beyond the endof the second zone 317 b, wherein the defective diaper falls is nolonger held with suction forces and falls away from the carrier surface317 of the first carrier to the reject bin 336.

As shown in FIG. 4, the reject bin 336 may also be located below thefirst carrier 316, the pick-up zone 316, and/or the transfer apparatus320, thus gravitational forces may also help guide the defective article100R downward toward the reject bin 336 after separating from thecarrier member 324 and/or first carrier 316. It is also to beappreciated the pneumatic system 500 operably connected with the firstcarrier 316 and the pneumatic system 550 operably connected with thetransfer apparatus 320 may be configured to operate together orindividually in various ways in response to a reject command 1000.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for rejecting defective absorbentarticles from a web converting manufacturing process, the methodcomprising the steps of: converting a substrate and component parts intoa continuous length of absorbent articles; inspecting the substrate orcomponent parts with a sensor; communicating inspection parameters fromthe sensor to a controller; cutting the continuous length of absorbentarticles into discrete absorbent articles; identifying defectivediscrete absorbent articles based on the inspection parameters;advancing the discrete absorbent articles in a machine direction on afirst carrier; transferring discrete absorbent articles from the firstcarrier onto carrier members at a first position proximate the firstcarrier; applying a vacuum pressure to the carrier members to hold thediscrete absorbent articles on the carrier members; moving carriermembers from the first position proximate the first carrier to a secondposition proximate a second carrier; and transferring discrete absorbentarticles from the carrier members to the second carrier; and rejectingdefective discrete absorbent articles before the defective absorbentarticles are transferred to the second carrier.
 2. The method of claim1, further comprising the step of: orbiting the carrier members aroundan axis of rotation.
 3. The method of claim 1, wherein each carriermember comprises a carrier surface and an aperture in the carriersurface, and wherein the step of applying a vacuum pressure furthercomprises placing the aperture in fluid communication with a vacuumsystem.
 4. The method of claim 3, wherein the step of rejectingdefective absorbent articles further comprises releasing one defectiveabsorbent article from one carrier member while moving from the firstposition to the second position.
 5. The method of claim 4, wherein thestep of rejecting defective discrete absorbent articles furthercomprises interrupting the fluid communication between the aperture andthe vacuum system.
 6. The method of claim 5, wherein the step ofrejecting defective discrete absorbent articles further comprisesplacing the aperture in fluid communication with a positive pressuresystem.
 7. The method of claim 1, wherein the step of rejectingdefective absorbent articles further comprises preventing one or moredefective absorbent articles from being transferred from the firstcarrier to one or more carrier members.
 8. The method of claim 7,wherein the step of rejecting defective discrete absorbent articlesfurther comprises interrupting the fluid communication between theaperture and the vacuum system at the first position proximate the firstcarrier.
 9. The method of claim 8, wherein the step of rejectingdefective discrete absorbent articles further comprises placing theaperture in fluid communication with a positive pressure system at thefirst position proximate the first carrier.
 10. A method for rejectingdefective absorbent articles from a web converting manufacturingprocess, the method comprising the steps of: converting a substrate andcomponent parts into a continuous length of absorbent articles;inspecting the substrate or component parts with a sensor; communicatinginspection parameters from the sensor to a controller; cutting thecontinuous length of absorbent articles into discrete absorbentarticles; identifying defective discrete absorbent articles based on theinspection parameters; advancing the discrete absorbent articles in amachine direction on a first carrier; orbiting the carrier members abouta first axis of rotation; transferring discrete absorbent articles in afirst orientation from the first carrier onto the carrier members;applying a vacuum pressure to the carrier members to hold the discreteabsorbent articles on the carrier members; rotating the carrier membersabout a second axis of rotation to place the discrete absorbent articlesin a second orientation; and transferring discrete absorbent articlesfrom the carrier members to the second carrier in the secondorientation; and rejecting defective discrete absorbent articles beforethe defective absorbent articles are placed in the second orientation.11. The method of claim 10, wherein each carrier member comprises acarrier surface and an aperture in the carrier surface, and wherein thestep of applying a vacuum pressure further comprises placing theaperture in fluid communication with a vacuum system.
 12. The method ofclaim 11, wherein the step of rejecting defective discrete absorbentarticles further comprises interrupting the fluid communication betweenthe aperture and the vacuum system.
 13. The method of claim 12, whereinthe step of rejecting defective discrete absorbent articles furthercomprises placing the aperture in fluid communication with a positivepressure system.
 14. The method of claim 13, wherein the step ofrejecting defective absorbent articles further comprises removing onedefective absorbent article from one carrier member.
 15. The method ofclaim 13, wherein the step of rejecting defective absorbent articlesfurther comprises preventing one defective absorbent article from beingtransferred from the first carrier to one carrier member.
 16. A systemfor rejecting defective absorbent articles, the system comprising: astator member including an arc shaped manifold, a first port, and asecond port; an arc shaped insert positioned inside the manifold andmovably connected with the manifold, wherein a portion of the manifoldhousing the insert defines a first zone, and a remaining portion of themanifold defines a second zone; an actuator connected with the insertand adapted to move the insert to a first position and a secondposition, wherein the first zone of the manifold is in fluidcommunication with the first port when insert is in the first position,and the first zone of the manifold is in fluid communication with thesecond port when the insert is in the second position; a support memberextending radially outward from a first axis of rotation and adapted torotate about the first axis of rotation; and a carrier member connectedwith the support member, the carrier member including an aperturedcarrier surface, the aperture carrier surface being in intermittentfluid communication with the manifold as the support member rotatesabout the first axis of rotation.
 17. The system of claim 16, whereinthe second zone of the manifold is in continuous fluid communicationwith the second port.
 18. The system of claim 17, further comprising: apositive air pressure system fluidly connected with the first port; anda vacuum air system fluidly connected with the second port.
 19. Thesystem of claim 18, further comprising: an inspection sensor; acontroller operably connected with the inspection sensor and theactuator, the controller configured to receive an inspection parameterfrom the inspection sensor to generate a reject command based on theinspection parameter; and wherein the actuator moves the insert to thefirst position in response to a reject command.
 20. The system of claim19, wherein the carrier member is pivotally connected with the supportarm, and wherein the carrier member is adapted to pick-up an absorbentarticle in a first orientation and pivot with respect to the supportmember to place the absorbent article in a second orientation.